Apparatus for securing insulation panels to a supporting structure and ceiling support assembly incorporating the same

ABSTRACT

An apparatus for securing insulation panels to a supporting structure and having an elongate body and a first end including a tip configured to pierce into the insulation panel and into the supporting structure. The apparatus further includes a depth stop disposed along the elongate body and adjacent said tip the depth stop providing a first abutment surface for a face of said supporting structure and a second end having associated therewith a second abutment surface, whereby a distance between the first abutment surface and the second abutment surface is less than or equal to a minimum thickness of said insulation panels.

The present invention relates to an apparatus for securing insulationpanels to a face of a supporting structure and, in particular, to ascrew apparatus adapted to secure expanded polystyrene foam panelsdirectly to roof truss elements. The invention further relates to aceiling support assembly incorporating the screw apparatus which ensuresthat the lower face of a plurality of ceiling support battens aredisposed at even, level heights ready for ceiling panel attachment.

BACKGROUND OF THE INVENTION

The purpose of roof insulation is well known in that it provides somelevel of environmental control in an area inside a home or building.Typically, a home or building will include a roof structure including aplurality of metal or wooden roof trusses which incorporate horizontallyextending roof truss sections to which ceiling panels are directlyattached. Insulation is usually provided in the form of ceiling battsadapted to be installed between the horizontally extending roof trussbeams above the ceiling panels. The batts serve to reduce heat transferthrough the roof, improving comfort and energy efficiency.

In more recent years, the use of rigid cellular insulation (RCI) forproviding insulation to walls and roof has become glowingly popular. Forexample, the present Applicant has been involved in the development ofan expanded polystyrene foam structural panel for such purposes.Benefits to using foam panels include being light-weight, having highinsulation properties, and being less prone to causing harm anddiscomfort to installers.

However, the fixing of foam panels directly to the lower face ofhorizontal roof truss elements using known fastening means has presentedproblems. For example, known apparatus for fastening the panels to theroof truss elements often restricts the positioning of panels whichmakes installation of the panels very cumbersome. This was a result ofthe panel support apparatus, typically a bracket, being hung from anopen edge of the truss section and configured such that the edges of twobutting panels were engaged and secured by the support device. Theskilled addressee would understand that such a configuration severelylimits the positional freedom of the panels.

Another problem associated with prior art means of securing insulationpanels directly to a supporting truss element is that, mounting ofceiling panels there beneath becomes problematic owing to variations inthe thickness of the panels. For example, the foam panel height at oneend of the room could be different to the foam panel height at anopposite end of the room, thereby increasing the possibility of slopedor uneven ceiling panels.

There is a general need in the industry for an apparatus/assemblycapable of securing insulation panels, such as foam insulation panels,directly to supporting structures such as wall stud or roof trusselements, and in the latter case, ensuring that ceiling panels are fixedat even distances relative to the roof truss chords.

Any discussions of documents, acts, materials, devices, articles or thelike, which has been included in the present specification is solely forthe purpose of providing a context for the present invention. It shouldnot be taken as an admission that any or all of the previous discussionforms part of the prior art base or was common general knowledge in thefield of the invention as it existed before the priority date or any ofthe claims herein.

SUMMARY OF THE INVENTION

In one aspect, the present invention provides an apparatus for securinginsulation panels to a supporting structure, the apparatus including:

an elongate body;

a first end including a tip configured to pierce into the insulationpanel and into the supporting structure;

a depth stop disposed along the elongate body and adjacent said tip,said depth stop providing a first abutment surface for a face of saidsupporting structure; and

a second end having associated therewith a second abutment surface,whereby a distance between the first abutment surface and the secondabutment surface is less than or equal to a minimum thickness of saidinsulation panels.

In an embodiment, the second abutment surface is associated with a headportion of the apparatus.

In an embodiment, the supporting structure is an overhead structuralelement such as a roof truss element, wherein said face is a lower faceof the roof truss element.

In an alternate embodiment, the supporting structure is an uprightelement such as a wall stud, wherein said face is an outer face of thewall stud.

In an embodiment, the insulation panels are rigid cellular insulation(RCI) panels.

In a further embodiment, the insulation panels are expanded polystyrenefoam panels.

In an embodiment, the apparatus is a screw apparatus whereby the tip ispointed and includes a thread on an outer surface of the apparatus bodyadjacent the tip, whereby tightening of the apparatus into the panel andinto the supporting structure involves screwing the screw apparatus.

In an embodiment, the head portion is a hexagonal screw head.

In an embodiment, the depth stop is a shoulder formed integrally withthe apparatus body having of a larger cross sectional dimension than thebody. The skilled addressee would understand that in having a body ofsmaller cross sectional dimension to that of the depth stop,manufacturing costs and thermal bridging from the supporting structureis reduced. This is particularly important when the supporting structureis a truss element. such that if the screw apparatus included a heavymetal body of the same or larger cross section than the depth stop, theability to transfer heat from the truss element would be greater.

In an embodiment, the screw apparatus including the tip, depth stop,body and head form an integral structure.

In an embodiment, the tip is configured to screw into solid roof trusselement such as a wooden truss section.

In an alternate embodiment, the tip is configured to screw into a rolledmetal truss element.

In another aspect, the present invention provides an assembly including:

-   -   an apparatus configured for securing insulation panels to an        overhead supporting structure in accordance with the above        described paragraphs; and    -   a bracket including an upper face configured to be sandwiched        between the insulation panel and the head portion of the        apparatus, the bracket further including hook means suspended        there from for supporting a ceiling support structural member.

In an embodiment, the bracket is an inverted U-shaped bracket includinga longitudinal upper face and two side walls extending downwardly therefrom.

In an embodiment, the bracket upper face includes a slot having anopening at one end thereof and a linear portion, the linear portionbeing of a dimension to accommodate sliding of the apparatus elongatebody there along but not allowing for retraction of the depth stop, theopening being of a dimension to allow for insertion of the apparatusincluding the depth stop.

In an embodiment, the hook means are in the form of downward extensionsof each corner of each side wall into a hook such that each side wallincludes two inwardly facing hook sections and each bracket includesfour hook sections at lower corners thereof.

In an embodiment, the ceiling support structural member is a battenincluding a lower surface to which a ceiling panel is adapted to befixed, and upright, slightly diverging side walls which terminate inhorizontally extending flanges adapted to be supported inside each pairof inwardly facing hook sections.

In an embodiment, the side walls are compressible such that the width ofthe batten can be manually decreased in order for the flanges to fitbetween the hook sections, and then engage inside the hook sections byreleasing the side walls to their original form.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described with reference to theaccompanying drawings which illustrate exemplary embodiments of thepresent invention, wherein:

FIG. 1 is a perspective view of an embodiment of a screw apparatus ofthe present invention for securing an insulation panel to a roof trusselement;

FIG. 2 is a perspective view of an embodiment of a screw apparatus forsecuring an insulation panel to a roof truss element according to analternate embodiment;

FIG. 3 is a top, perspective view of an embodiment of a ceiling battensupport bracket forming part of an assembly of the present invention;

FIG. 4 is a top, perspective view of a plurality of roof truss elementsincluding insulation panels propped up against a lower face of the rooftruss elements to form an insulating layer;

FIG. 5 is a top, perspective view of the roof truss elements and proppedinsulation panels of FIG. 4, and assemblies according to an embodimentof the invention whereby each assembly includes a screw apparatus and aceiling batten support bracket for securing the panels to the roof trusselements and presenting a means of attachment for a plurality of ceilingsupport battens;

FIG. 6 is a top, cutaway perspective view of the components shown inFIG. 5 in a fully assembled state, and ceiling support battens supportedat right angles to the direction of the roof truss elements by axiallyaligned and spaced apart ceiling batten support brackets;

FIG. 7 is a top, perspective view of the components of FIG. 6 in a fullyassembled state, and ceiling panels attachable to a lower face of theceiling support battens;

FIG. 8 is a top, cutaway perspective view of the components of FIG. 7 ina fully assembled state;

FIG. 9 is a top, perceptive view of the components of FIG. 7 in a fullyassembled state;

FIG. 10 is an enlarged perspective view of an embodiment of an assemblyof the invention including a screw apparatus used to secure aninsulation panel to a roof truss element and an associated bracketpartially supporting a ceiling support batten to which a ceiling panelis attached;

FIG. 11A is a cross sectional view of an embodiment of an assembly asshown in FIG. 10 whereby the bracket is slightly embedded in theinsulation panel;

FIG. 11B is a cross sectional view of an embodiment of an assembly asshown in FIG. 10 whereby the bracket is flush with a lower face of theinsulation panel; and

FIG. 12 is a cross sectional view of an embodiment of the inventionwhereby the roof truss elements are rolled metal sections.

DETAILED DESCRIPTION OF EMBODIMENT(s) OF THE INVENTION

The following detailed description of the invention refers to theaccompanying Figures. Although the description includes exemplaryembodiments, other embodiments are possible, and changes may be made tothe embodiments described without departing from the spirit and scope ofthe invention. Wherever possible, the same reference numbers will beused throughout the embodiments and the following description to referto the same and like parts.

Reference to a “structural element”, “truss element”, “roof trusselement” or “wall stud” herein is not intended to limit the invention toany one type, shape or orientation of supporting structure or structuralelement thereof. For example, in one embodiment, the supportingstructure could form part of a roof truss, and thus may include withinits scope any type of roof truss element, including rolled steelsections or solid roof truss beams. The invention is not intended to belimited to use of a roof truss element. A truss element may be anupright element such as a wall stud for example. Provided the structureor surface thereof is of a sufficient structural integrity to supportmultiple components, and presents an attachment face, then it forms asuitable supporting structure as described herein.

The present invention relates to an apparatus and assembly for securinginsulation panels directly to a face of a supporting structure, such asa horizontal roof truss element or an upright wall stud. When secured toan overhead supporting structure, the assembly provides a means forattachment of ceiling panels a spaced distance below the insulatingpanels. In one aspect, the invention provides an apparatus for securingthe insulation panels which overcomes various deficiencies associatedwith prior art methods of securing the panels. In another aspect, theinvention provides an assembly for supporting a plurality of ceilingsupport battens at a level height.

According to one embodiment, the apparatus is in the form of a screwapparatus 10 as shown in FIG. 1 including a longitudinal body 12 havinga screw head 14 at one end and a threaded section 16 at, or adjacent to,an opposed end. Disposed inwardly of the threaded section 16 is a depthstop 18 in the form of a shoulder providing an abutment surface 20. Thethreaded section 16 shown in FIG. 1 is of the type for screwing into asolid roof truss element, but the tip of the apparatus 10 could beconfigured a number of other ways, including for screwing into thinsteel sections and the like as described further below.

The distance between the abutment surface 20 and a flat surface 22associated with the screw head 14 will be referred to herein as the“critical dimension” of the screw apparatus 10. However, use of the word“critical” should in no way be considered limiting, or interpreted asreferencing a preferred embodiment of the invention. In addition, thesurface 22 need not necessarily be associated with the screw head, butcould be in the form a second depth stop for example.

A screw apparatus 12 according to an alternate embodiment is shown inFIG. 2 whereby the threaded section 16 includes a “self-drilling” typetip 23 for particular use in screwing into rolled metal elements such asthe substantially Z-shaped rolled steel element shown in FIG. 12, asopposed to a conventional thread for drilling into solid truss elementsas shown in the other drawings. The assembly for providing an evensurface for installation of ceiling panels, according to one embodiment,includes the screw apparatus 10 of FIG. 1 and a ceiling support bracket24 as shown in FIG. 3.

The bracket 24 is of an inverted U-shaped, longitudinal dimensionincluding two vertical side walls 26 and an upper wall 28. Each verticalside wall terminates at each lower corner into downwardly extending andinwardly directed hook sections 30 such that there are four hooksections associated with each bracket 24. The hook sections 30 areadapted to suspend and support a ceiling support batten 30 as will bedescribed in more detail below.

The upper wall 28 includes a longitudinal slot 32 including at one end acircular opening 34 of sufficient dimension to allow for insertion ofthe screw apparatus body 12 as well as the depth stop 18, and a linearportion 36 of a sufficient dimension to allow for sliding of the body12, but not large enough to allow for retraction of the depth stop 18.Further, the upper wall 28 terminates at its longitudinal ends in smalldownwardly sloped ramps 35 which are intended to assist an installer byallowing the bracket 24 to slide sideways more easily duringpositioning/tightening, as described in more details below.

The way in which the screw apparatus 10 acts to secure an insulationpanel to a supporting structure, and thereby overcome some of thedeficiencies associated with prior art methods of doing so, will now bedescribed with reference to FIGS. 4 to 10 which demonstrate step by stepthe process of installing insulation and ceiling panels to a roof trussin accordance with an embodiment of the present invention. The followingparagraphs will also demonstrate how an assembly incorporating both thescrew apparatus 10 and the bracket 24 provides for the ceiling panels tobe secured at an even height relative to the overhead roof trusses.

FIG. 4 illustrates three horizontal roof truss elements 38 forming partof three roof truss assemblies (not shown in full) with a plurality offoam insulation panels 40. At this stage of installation, the panels arebeing held in place ready to be fastened or secured to the overhead roodtruss elements, and can be held by a ground prop (not shown), or by oneor more installers, although the present invention is not intended to belimited to any one of these means of support.

In the embodiment shown, the panels include straight side edges whichare adapted to abut, but in an alternate embodiment (not shown), theinsulation panels could include side edges capable of engaging oneanother such that sides of the panels may engage with adjacent panels.This would simplify the installation procedure in that one would nolonger need to ensure that every panel is individually propped.

The next step of insulation is shown in FIG. 5 in which the screwapparatus 10 of FIG. 1 is shown together with the bracket 24 of FIG. 3.This assembly of components is used to secure the insulation panels 40to the overhead truss elements 38 and, as shown in FIG. 5, the screwapparatus 10 is adapted to be inserted through slot 32 of bracket 24. Afitter would insert the screw apparatus into the rounded opening 34 ofthe bracket slot 32 until the depth stop 18 is fully inserted, and thenslide the screw apparatus 10 along the linear portion 36 to anappropriate position, ensuring that the depth stop can no longer beretracted from the slot.

Once an installer has partially engaged the screw apparatus 10 with thebracket 24 like so, the screw can be used to pierce the insulation panelby tightening of the screw into the panel surface at a position beneathan overhead roof truss element. The installer continues tightening untilthe threaded section end of the screw apparatus contacts a lower face 42of the truss element 38. The installer then would continue to tightenthe screw apparatus to thereby pierce the truss element and continuetightening until the depth stop surface 20 abuts the lower face 42 ofthe truss at which point further tightening will be opposed by the lowerface 42. It is at this time that the installer knows that no furthertightening is required.

In one embodiment the critical dimension of the screw apparatus body 12defined earlier is slightly less than the smallest measured thickness ofeach insulation panel to ensure that the bracket 24 will always create atight, rattle-free fit in that the bracket becomes slightly embedded inthe foam as shown in FIG. 11 a.

Owing to the nature by which such insulation panels are manufactured, itis estimated that the panel thickness may vary. For example, one panelthickness may vary compared to another panel thickness by up to 3 mm ormore. The skilled addressee would understand now why the criticaldimension of the screw apparatus is an important factor. If the criticaldimension is larger than a maximum thickness of the foam panels, thefoam panel will be allowed to rattle which is undesirable. If thecritical dimension is the same as the thickness of the foam panel, asshown in FIG. 11 b, this may still be adequate. However, in anembodiment that ensures that the panel is secured free of movement, thisdimension should be made slightly less than the minimum panel thickness.It is also evident in FIG. 11 a how the upper face of the bracket 24effectively acts as a washer for the screw apparatus 10 in that itprovides an abutting surface for the screw head surface 22.

When the insulation panels are propped in position, the installers areunable to see the overhead truss. However, the approximate position ofthe truss can be estimated in that they are visible at the edge of thepanels and they also align with the wall studs (not shown) that arevisible from within the building. This is how the installer will knowapproximately where to pierce the insulation panel to reach the trusselement. Fitters are quite accustomed to lining up assemblies like soand it is not envisaged that this will pose a problem. There are alsonow devices available to send and provide an audible/visible alarm toindicate where a beam is hidden behind a panel. FIG. 6 illustrates thenext step of attaching ceiling support battens to aligned brackets 24secured beneath the insulation panels. The skilled addressee wouldunderstand the importance of having brackets which are secured to thepanels in appropriate alignment in order to accommodate a batten. Eachbatten 44 is substantially U-shaped with a horizontal base 46 andoutwardly diverging, upright side walls 48. The side walls terminate insubstantially horizontal flanges 50 which are the portions dimensionedto be accommodated and secured inside inwardly directed hook sections 30of each bracket.

When fixed to the insulation panels, each longitudinal bracket isaligned parallel with the longitudinal overhead roof truss element, andthe hook sections 30 thereof are configured such that the battens willbe accommodated at right angles to the overhead roof truss elements. Theslot 32 in the brackets facilitates the alignment of brackets associatedwith spaced apart roof truss elements in that spaced apart bracketsaccommodating a single batten are able to be appropriately aligned withone another just prior to final tightening of the screw apparatus' 10.

Alignment of spaced brackets can be achieved any number of waysincluding by laser alignment or by visible inspection. The configurationof each batten is such that the outwardly diverging side walls can beslightly compressed until the batten is appropriately centered insidethe hook sections 30 and then released so that the flanges 50 enter thehook sections and are thereby restricted from downward movement.

The skilled addressee would appreciate that, in carrying out theabovementioned steps, a plurality of batten support brackets 24 acrossan entire ceiling are positioned an equal distance away from a lowerface of a roof truss element, and battens suspended there from are thusalso disposed at an even, level height. The base surface 46 of eachbatten is then ready to accommodate ceiling panels 52, such asplasterboard panels, as shown in FIG. 7.

The panels 52 can be attached to the base surface 46 of each battenusing any conventional means, including by using screw fasteners (notshown). FIGS. 8 and 9 show the fully assembled and installed views ofeach of the prior described components. It can be appreciated, inparticular in FIG. 8, that a clearance is created between the ceilingpanels 52 and the foam panels 40 there above. This clearance is equal tosubstantially the combined height of the engaged bracket 24 and batten44.

In one embodiment, the engaged bracket and batten are dimensioned suchthat they create an approximately 40 mm air cavity 54 between theunderside of the insulation panels and the top surface of the ceilingpanels, allowing for fitment of ceiling fixtures and other utilities(not shown).

FIG. 10 shows an enlarged view of the fully assembled screw apparatus 10and an assembly including a screw apparatus 10 and a batten supportbracket 24 assembly according to an embodiment.

In one embodiment the thickness of the insulation panels ranges betweenapproximately 113 mm to 115 mm and is constructed of expandedpolystyrene foam which allows for the screw to pierce through the panel.In this example embodiment, the critical dimension of the screwapparatus 10 may accordingly be 112 millimeters, that is, slightly lessthan the minimum thickness of the insulation panel. The skilledaddressee would understand that the resulting engagement would besimilar to that shown in FIG. 11 a which, as mentioned earlier, showsthe bracket slightly embedded into the foam panel. The invention is inno way intended to be limited to the above described dimensions and/orthickness variations.

As mentioned earlier, the present invention is not intended to belimited to any on type of roof truss element. For example, FIG. 12illustrates a further embodiment whereby the roof truss element is asubstantially Z-shaped rolled steel truss element 56 and the screwapparatus 10 is of the type shown in FIG. 2 adapted for screwing thethickness of steel as shown. As mentioned earlier, it is to beunderstood that variations to the type of roof truss element and themeans of fastening the apparatus 10 to the truss are considered withinthe scope of the invention. For example, the truss element could indeedbe an upright wall stud.

The present invention thus provides an apparatus 10 which overcomes someof the deficiencies associated with prior art methods of securinginsulation panels to a supporting structure such as an underside ofhorizontally extending roof truss elements, in that an installer cansimply prop up the panels and pierce the apparatus through the panel andinto the truss without the need to ensure that the insulation panels arepositioned or arranged in any particular way. That is, the apparatus 10need not extend alongside edges of abutting panels in order to supportthe two adjacent panels as was required in prior art apparatus known tothe Applicant.

In another aspect, the invention provides an assembly including such ascrew apparatus 10 in association with a bracket 24 which is clamped tothe underside of the foam panel using the aforementioned screw apparatus10 and configured to provide a support for a plurality of battensextending at right angles to the roof truss elements at even distancesfrom the roof truss elements. That is, a lower surface of each battenprovides an even surface across an entire ceiling to which an installermay attach ceiling panels.

Thus, insulation and ceiling fitters are able to install ceilinginsulation panels to a higher degree of screw position flexibility whilemaintaining a consistent drop height from the roof truss element, orother supporting structure. In addition, the configuration provides acavity between the insulation panels and the top surface of the ceilingpanels, thereby accommodating any required utilities such as electricalwiring.

The reference to any prior art in this specification is not, and shouldnot be taken as, an acknowledgement or any suggestion that the prior artforms part of the common general knowledge in Australia.

1. An apparatus for securing insulation panels to a supportingstructure, the apparatus including: an elongate body; a first endincluding a tip configured to pierce into the insulation panel and intothe supporting structure; a depth stop disposed along the elongate bodyand adjacent said tip, said depth stop providing a first abutmentsurface for a face of said supporting structure; and a second end havingassociated therewith a second abutment surface, whereby a distancebetween the first abutment surface and the second abutment surface isless than or equal to a minimum thickness of said insulation panels. 2.An apparatus as in claim 1 wherein the second abutment surface isassociated with a head portion of the apparatus.
 3. An apparatus as inclaim 1 wherein the supporting structure is an overhead structuralelement such as a roof truss element, wherein said face is a lower faceof the roof truss element.
 4. An apparatus as in claim 1 wherein thesupporting structure is an upright element such as a wall stud, whereinsaid face is an outer face of the wall stud.
 5. An apparatus as in claim1 wherein the insulation panels are rigid cellular insulation (RCI)panels.
 6. An apparatus as in claim 1 wherein the insulation panels areexpanded polystyrene foam panels.
 7. An apparatus as in claim 1 whereinthe apparatus is a screw apparatus whereby the tip is pointed andincludes a thread on an outer surface of the apparatus body adjacent thetip, whereby tightening of the apparatus into the panel and into thesupporting structure involves screwing the screw apparatus.
 8. Anapparatus as in claim 1 wherein the head portion is a hexagonal screwhead.
 9. An apparatus as in claim 1 wherein the depth stop is a shoulderformed integrally with the apparatus body having of a larger crosssectional dimension than the body.
 10. An apparatus as in claim 1wherein the screw apparatus including the tip, depth stop, body and headform an integral structure.
 11. An apparatus as in claim 1 wherein thetip is configured to screw into solid roof truss element such as awooden truss section.
 12. An apparatus as in claim 1 wherein the tip isconfigured to screw into a rolled metal truss element.
 13. An assemblyincluding: an apparatus configured for securing insulation panels to anoverhead supporting structure in accordance with the above describedparagraphs; and a bracket including an upper face configured to besandwiched between the insulation panel and the head portion of theapparatus, the bracket further including hook means suspended there fromfor supporting a ceiling support structural member.
 14. An assembly asin claim 13 wherein the bracket is an inverted U-shaped bracketincluding a longitudinal upper face and two side walls extendingdownwardly there from.
 15. An assembly as in claim 14 wherein thebracket upper face includes a slot having an opening at one end thereofand a linear portion, the linear portion being of a dimension toaccommodate sliding of the apparatus elongate body there along but notallowing for retraction of the depth stop, the opening being of adimension to allow for insertion of the apparatus including the depthstop.
 16. An assembly as in claim 13 wherein the hook means are in theform of downward extensions of each corner of each side wall into a hooksuch that each side wall includes two inwardly facing hook sections andeach bracket includes four hook sections at lower corners thereof. 17.An assembly as in claim 13 wherein the ceiling support structural memberis a batten including a lower surface to which a ceiling panel isadapted to be fixed, and upright, slightly diverging side walls whichterminate in horizontally extending flanges adapted to be supportedinside each pair of inwardly facing hook sections.
 18. An assembly as inclaim 17 wherein the side walls are compressible such that the width ofthe batten can be manually decreased in order for the flanges to fitbetween the hook sections, and then engage inside the hook sections byreleasing the side walls to their original form.